WOODWORKS: BEGINNER PROJECT 2007-2008

NESTING TRAYS

Great for getting organized or serving snacks, these sturdy trays are easy to build, thanks to their simple rabbeted corner joints and template-routed
handles. All you need is a table saw with a dado set, a router table and a drill press. You may have saved enough scrap pieces from other projects to
build the trays and the jigs, but even if you have to buy lumber and plywood, you can make this trio of trays inexpensively. And when they're all
assembled, you'll learn more about applying and using stains and finishes to protect the wood and keep it looking beautiful.

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CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS

TOOLS REQUIRED SHOPPING LIST

Recommended wood: Birch
Hand Tools
Alternate wood: Pine
– Toggle clamps (2)
– Adjustable-jaw clamps (4) 1/2" x 5-1/2" birch: 11 lin. ft.
– Mallet 1/2" x 3-1/2" birch: 5 lin. ft.
– Chisel 1/4" birch plywood: 2' x 4' piece
Power Tools 3/4" brads
– Table saw with combination
rip/crosscut blade and dado blades CUTTING LIST
– Router table, 3/4" dia. straight-cut
bit, flush-trim bit Overall Dimensions:
– Drill press, 7/8"- and 1"- dia. Large Tray 4-1/4" x 13-1/2" x 20"
Forstner bits Medium Tray 3-3/4" x 12-1/4" x 18-3/4"
– Jigsaw Small Tray 3-1/4" x 11" x 17-1/2"
– Oscillating spindle sander or sanding Routing Jig 3-1/4" x 10" x 20"
drum for drill press, 3" and 3/4"
spindles Kay Part Pcs. Dimensions
Miscellaneous Large Tray
– Pencil A1 End 2 1/2" x 4-1/4" x 13"
– Tape measure A2 Side 2 1/2" x 2-3/4" x 20"
– Safety glasses A3 Bottom* 1 1/4" x 12-27/32" x 19-11/32"
– Carpenter's glue Medium Tray
– 120-, 180- and 220-grit sandpaper B1 End 2 1/2" x 3-3/4" x 11-3/4"
– Clean, lint-free cloths B2 Side 2 1/2" x 2-1/4" x 18-3/4"
– Respirator B3 Bottom* 1 1/4" x 11-19/32" x 18-3/32"
– Gloves for finishing Small Tray
– Mineral spirits (for oil-based stains C1 End 2 1/2" x 3-1/4" x 10-1/2"
and finishes) C2 Side 2 1/2" x 1-3/4" x 17-1/2"
– Water-filled metal container with C3 Bottom* 1 1/4" x 10-11/32" x 16-27/32"
tight-fitting lid (for oil-based stains Routing Jig
and finishes) T Base 1 1/2" x 10" x 20"
– Minwax® Wood Finish™ Stain Brush U Fence 1 1/2" x 5-3/4" x 20"
or other good quality, natural-bristle V Stop 2 1/2" x 2-3/4" x 3-1/2"
brush (for oil-based stains and W Medium end spacer 2 1/2" x 5/8" x 2-1/2"
finishes) X Medium bottom spacer 1 1/2" x 1/2" x 11-3/4"
– Minwax® Polycrylic® Brush or other Y Small end spacer 2 1/2" x 1-1/4" x 2-1/2"
good quality, synthetic-bristle brush Z Small bottom spacer 1 1/2" x 1" x 10-1/2"
(for water-based stains and finishes) * 1/4" birch or maple plywood

WOOD FINISHING PRODUCTS

Recommended Finish
Prep: Minwax® Water-Based Pre-Stain Wood Conditioner
Stain: Minwax® Water-Based Wood Stain Spice, Mediterranean
Olive, and Parchment
or
Minwax® Water-Based Wood Stain™ Accents™ Midnight
Blue, Botanical, and English Oak
Finish: Minwax® Polycrylic® Protective Finish gloss
Alternate Finish
Prep: Minwax® Pre-Stain Wood Conditioner
Stain: Minwax® Wood Finish™ Dark Walnut/Gun
Stock/Puritan Pine
Finish: Minwax® Fast-Drying Polyurethane gloss
or
Minwax® Clear Brushing Lacquer gloss

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 CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS
BEFORE YOU BEGIN
Good craftsmanship begins and ends with good work habits, so make
the following steps part of your routine workshop practice. If you have
any doubts or questions about how to proceed with a project, always
discuss them with your shop instructor.
• Carefully and fully review plans and instructions before putting a
tool to the project lumber.
• Work sensibly and safely. Wear safety goggles when doing work
that creates flying chips and sawdust; wear the appropriate
respirator whenever making sawdust or working with thinners
or other solvents.
• At the end of every work session, clean up your shop area and put
away all portable tools.
CUTTING AND ASSEMBLY
PROCEDURE
1. Cut all the parts on the CUTTING LIST.
Cut the Rabbet Joints
2. Set the height of the router bit (or dado head if you're using a table
saw) to 1/4", half the thickness of the material.
3. Set the fence location so the tip of the router bit is 1/2" away from
the face of the fence. Make a test cut in scrap and check the fit of the
rabbet joint against a tray end. The end should nest perfectly inside
the rabbet.
4. Machine the rabbet into both ends of each of the tray sides. Use
a piece of scrap to support the piece and hold it square. This also
provides backup so the side doesn't chip out as the bit exits the cut.
All of these cuts are made with the good (outside) face up.
Make the Routing Jig
5. Refer to Figs. 3 and 4 when making the jig. Use glue and 3/4" brads
to fasten the fence (U) and the stops (V) to the base (T).
6. Use the end profile of the large tray (Fig. 4) as a pattern when you
make the routing jig (Fig. 3). First, transfer the curved edge profile
to the jig's base. Then drill 1"-dia. holes with a Forstner bit to establish
the ends of the handle hole. Finish rough-cutting the handle hole with a
jigsaw. Then rough-cut the edge profile.
7. Smooth the routing jig's edge profile using an oscillating spindle
sander or a sanding drum in your drill press. Install a 3/4"-dia. spindle
or drum to smooth the handle hole.
8. Fasten the fence flush with the bottom of the jig's base.
9. Place one of the large end-piece blanks on the jig. The top of the
blank should be flush with the top of the jig. Center the blank and then
install the stops. Mount the toggle clamps.
Rout the Ends
10. Draw edge profiles and handle holes on all the end blanks after
installing them in the jig. Make spacers (W, X, Y and Z, Fig. 3) to
position the medium and small blanks.
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11. Rough-saw all the curved profiles about 1/16" away from the
pattern lines. To rough out the handle holes, drill 7/8"-dia. holes and
use a jigsaw to saw out the waste.
12. Rout the edge profiles with a top-bearing flush-trim bit (Fig 5).
Then rout the handle holes (Fig 6). Assure the workpiece is securely
held. With the router unplugged, center the bit inside the roughsawn
opening. Hold the jig steady so the bit spins freely when you power up.
Then rout counterclockwise.
Cut the Groves
13. Cut 3/16" deep grooves for the plywood bottoms (A3, B3 and C3)
in the sides and ends. Because 1/4"-thick plywood is often undersize,
you can't use a dado set. Use your regular blade and make two passes.
Adjust the fence between passes to widen the groove enough to allow
the plywood to insert easily yet snugly.
Assemble the Trays
14. Assemble the boxes without glue to assure everything fits.
15. Disassemble the boxes for sanding. Finish-sand with 100-, 180-
and 220-grit sandpaper.
16. Assemble the trays by brushing glue into the rabbets and into
the grooves. Assemble two sides and one end, clamping across the
end and insert the plywood (Fig. 7). Use clamping blocks to protect
the wood. Insert strips of paper towel between the blocks and the sides
to absorb excess glue. Assemble the other end and secure it with
another clamp. Check the trays for square after they're clamped and
adjust as necessary.
17. After the glue has dried, remove the clamps. Check for any
squeezed-out glue and carefully remove it with a chisel. Smooth
resulting rough spots with 220-grit sandpaper.
STAINING AND FINISHING
Woodworker's Tip: Though you may be tempted to cut short
your sanding, preparation and application time, don't do it.
These tasks are very important steps in obtaining a high-quality
finish. Remember, it is the finish, just as much as the fit and
smoothness of the parts that will have great bearing on how
people judge your craftsmanship. To ensure an excellent result,
follow the steps listed in this section and also the instructions
the finish manufacturer puts on its products.
FINISHING TIPS
• Test the stains and finishes you are planning to use on scraps of
wood. On the back of the scrap, mark the stain/finish combination
and the type of wood. Allow all samples to dry thoroughly before
making your final finish selection. Save your samples for quick
reference on future projects.
• All stains and finishes must be allowed to dry thoroughly between
coats. Remember that drying times can vary due to humidity and
other climatic conditions.
• If you have some leftover stain or finish, wipe the can rim so that
stain or finish in the rim won't dry out and prevent the lid from
forming a tight seal.
 CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS
• Brushes used for water-based products, such as Minwax®
Water-Based Wood Stains or Minwax® Polycrylic® Protective Finish,
must be cleaned with soap and water; brushes used for oil-based
finishes must be cleaned with mineral spirits.
18. Finish-sand the corners and any other rough spots with 220-grit
sandpaper. Dust off the piece and wipe it carefully with a clean, lint-free
cloth lightly dampened with mineral spirits.
Recommended Finish
19. Before applying Minwax® Water-Based Wood Stain to a hardwood
or softwood, apply Minwax® Pre-Stain Water-Based Wood Conditioner
following the directions on the can. Applying it will help to ensure even
absorption of stain and prevent blotchiness that can occur with some
woods. After 1 to 5 minutes, wipe off all excess conditioner using a
clean, soft cloth. Wait 15 to 30 minutes then use 220-grit or finer sand-
paper to sand off any “whiskers” raised by the conditioner. Proceed to
the staining within 2 hours.
20. Do the staining in two steps, starting on the interior surfaces and
then moving to the exterior surfaces. Apply the Minwax® Water-Based
Wood Stain you've chosen to the surface using either a nylon/polyester
brush or a cloth. Allow stain to penetrate no longer than 3 minutes.
While stain is still wet, wipe off all excess with a clean cloth that's been
lightly dampened with stain. Allow the piece to dry for 2 hours before
applying a second coat, if desired. Allow the piece to dry overnight
before applying the protective clear finish.
Woodworker's Tip: Minwax® Water-Based Wood Stain is
available in 6 wood tones, a White Wash Pickling Stain,
60 custom-mixed colors, and 8 bold Accents™ colors. This means
that you are not limited to just traditional wood colors (pine,
oak, walnut, etc.). Instead, you can pick and apply a color to
complement the décor of the room in which the piece will be
placed. For this reason, make sure you look over all of the
Minwax® color charts or go to minwax.com before making
your final selection.
21. After allowing the piece to dry overnight, apply Minwax®
Polycrylic® Protective Finish following the directions on the can.
Stir the can contents thoroughly before starting and periodically
repeat the stirring during your work session.
22. Working a small area at a time to maintain a wet edge, apply
the first coat. Work quickly and make the final strokes in each newly
finished section using with-the-grain brushstrokes.
23. Allow the finish to dry a minimum of 2 hours. Then sand lightly
with 220-grit or finer sandpaper wrapped around a soft backup block.
Thoroughly dust off and wipe all surfaces with a cloth lightly dampened
with water.
24. Repeat steps 21 and 22 to apply the second and final coat.
Alternate Finish
25. Apply the Minwax® Wood Finish™ you've chosen using a natural-
bristle brush and a clean, lint-free cloth following the directions on the
can. The brush will help you get the stain into the inside corners. Allow
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the Wood Finish™ to set for about 5 to 15 minutes, then wipe off any
excess. To achieve a deeper color, you may apply a second coat after
4-6 hours, repeating the application directions for the first coat. Allow
the stain to dry for 24 hours before applying the protective clear finish.
Woodworker's Tip: When wiping off stain, make certain that
your last wipe with the cloth goes with the grain of the wood. This
way, any stain you might miss during wipe-off will be visually
minimized by the wood grain.
Applying Fast-Drying Polyurethane
26. Apply Minwax® Fast-Drying Polyurethane following the directions
on the can, stirring it occasionally. Use a good quality, natural-bristle
brush. Allow the first coat to dry overnight.
27. The next day, sand all surfaces lightly with 220-grit or finer
sandpaper using with-the-grain strokes. Dust off and wipe all surfaces
with a cloth lightly dampened with mineral spirits. Apply a second coat
of polyurethane and set the piece aside to cure overnight.
28. The following day, sand all surfaces lightly with 220-grit sandpaper.
Dust off and wipe the piece with a cloth lightly dampened with mineral
spirits and apply the third and final coat of polyurethane.
Applying Clear Brushing Lacquer
29. Apply Minwax® Lacquer Sanding Sealer, if desired, following label
directions. Let dry at least 1 hour, then sand with 220-grit sandpaper,
moving in the direction of the grain. Remove all sanding dust.
30. Apply Minwax® Clear Brushing Lacquer, stirring it well before and
during use to rotate the product from the bottom to the top of the can.
NEVER SHAKE.
31. Apply a coat of lacquer using a high-quality natural- or
synthetic-bristle brush. Apply sufficient lacquer to seal open joints,
edges and end grain.
32. Let the first coat dry at least 2 hours, then apply a second coat.
33. Apply a third coat, repeating the steps above for each coat. Apply a
fourth coat, if desired.
34. After the final coat, allow at least 24 hours before using the trays.
PRODUCT SAFETY
For your safety and the safety of those you work with, always read the
safety warnings, which manufacturers print on their labels, and follow
them to the letter.
WARNING! Removal of old paint by sanding, scraping or other means
may generate dust or fumes that contain lead. Exposure to lead dust
or fumes may cause brain damage or other adverse health effects,
especially in children or pregnant women. Controlling exposure to lead
or other hazardous substances requires the use of proper protective
equipment, such as properly fitted respirator (NIOSH approved) and
proper containment and cleanup. For more information, call the
National Lead Information Center at 1-800-424-LEAD (in U.S.) or
contact your local health authority.
 CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS

DANGER: Rags, steel wool, other waste soaked with oil-based stains
and clear finishes, and sanding residue may spontaneously catch fire if
improperly discarded. Immediately place rags, steel wool, other waste
soaked with this product, and sanding residue in a sealed, water-filled
metal container. Dispose of in accordance with local fire regulations.
When using oil-based wood finishing products:
CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS.
Contents are COMBUSTIBLE. Keep away from heat and open flame.
VAPOR HARMFUL. Use only with adequate ventilation. To avoid over-
exposure, open windows and doors or use other means to ensure fresh
air entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory protec-
tion (NIOSH approved), or leave the area. Avoid contact with eyes and
skin. Wash hands after using. Keep container closed when not in use.
Do not transfer contents to other containers for storage.
FIRST AID: In case of eye contact, flush thoroughly with large
amounts of water for 15 minutes and get medical attention. For skin
contact, wash thoroughly with soap and water. In case of respiratory
difficulty, provide fresh air and call physician. If swallowed, call Poison
Control Center, hospital emergency room, or physician immediately.
DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.
Contains solvents which can cause permanent brain and nervous
system damage. Intentional misuse by deliberately concentrating
and inhaling contents may be harmful or fatal.
WARNING: This product contains a chemical known to the
State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.
CONFORMS TO ASTM D-4326. Contact a physician for more health
information.
When using lacquer:
CAUTIONS: CONTAINS ACETATES, ALCOHOLS, KETONES
AND XYLENE.
Contents are FLAMMABLE. Vapors may cause flash fires. Keep away
from heat, sparks, and open flame. During use and until all vapors are
gone: Keep area ventilated - Do not smoke - Extinguish all flames, pilot
lights and heaters - Turn off stoves, electric tools and appliances, and
any other sources of ignition. VAPOR HARMFUL. Use only with ade-
quate ventilation. To avoid overexposure, open windows and doors or
use other means to ensure fresh air entry during application and drying.
If you experience eye watering, headaches, or dizziness, increase
fresh air, or wear respiratory protection (NIOSH approved), or leave
the area. Avoid contact with eyes and skin. Wash hands after using.
Keep container closed when not in use. Do not transfer contents to
other containers for storage.
FIRST AID: In case of eye contact, flush thoroughly with large
amounts of water for 15 minutes and get medical attention. For skin
contact, wash thoroughly with soap and water. In case of respiratory
difficulty, provide fresh air and call physician. If swallowed, call Poison
Control Center, hospital emergency room, or physician immediately.
DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.
Contains solvents which can cause permanent brain and nervous
system damage. Intentional misuse by deliberately concentrating
and inhaling contents may be harmful or fatal.
WARNING: This product contains a chemical known to the
State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.

When using water-based wood finishing products:

CAUTIONS: Use Only With Adequate Ventilation. To avoid overexpo-
sure, open windows and doors or use other means to ensure fresh air
entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory
protection (NIOSH approved), or leave the area. Avoid contact with
eyes and skin. Wash hands after using. Keep container closed when
not in use. Do not transfer contents to other containers for storage.

FIRST AID: In case of eye contact, flush thoroughly with large

amounts of water. Get medical attention if irritation persists. If swal-
lowed, get medical attention immediately.

WARNING: This product contains a chemical known to the

State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.
CONFORMS TO ASTM D-4326. Contact a physician for more health
This project was adapted with permission from American
information.
Woodworker® magazine, AW Media LLC, an affiliate of New Track
Media LLC, Suite 180, 1285 Corporate Center Drive, Eagan, MN
55121. ©Copyright 2005. All rights reserved. For subscriptions
call toll-free: 1-800-666-3111.

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CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS

FIG 1. TRAY DETAILS

A3, B3, C3
1
/2"

3
/16" Deep Groove
A2, B2, C2

A1, B1, C1

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CONTINUED - WOODWORKS: BEGINNER PROJECT 2007-2008 NESTING TRAYS

FIG 2. RABBET SIDES

Cover Piece

3
/4" Dia. Straight Bit

Tray Side

FIG 3. ROUTING JIG

Fence 1/2" x 53/4" x 20" Stop 1/2" x 23/4" x 31/2"

Toggle Clamp

41/4"
Z
Y

X
W

Base 1/2" x 10" x 20"

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FIG 4. END PROFILE GRID

11/2"

13/8"

B1 C1

A1
1
/ 2"

1
/2"
1
/2"

FIG 5. ROUT EDGE PROFILES FIG 6. ROUT HANDLE HOLES

Flush Trim Bit

Spacers

FIG 7. ASSEMBLY

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